Anchor device for anchoring an elongated rod to the spine

ABSTRACT

A spinal fixation system includes a rod and anchor devices that include a bone engaging fastener having a head defining a spherical socket. A ball insert is placed within the socket and rotated so that the ball insert is juxtaposed with the socket. The anchor device further includes a yoke defining a yoke channel for receiving the rod and a stem engaged to the ball insert captured within the socket. A sleeve disposed between the yoke channel and the fastener head supports the rod. A set screw is operable to clamp the rod against the sleeve and draw the insert into engagement within the socket. A friction element in the form of a wave spring is disposed between the yoke and the fastener head is configured to releasably retain the yoke in at least one discrete position relative to the fastener.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.13/942,823, filed on Jul. 16, 2013, now U.S. Pat. No. 9,545,279, whichis a continuation of U.S. application Ser. No. 12/186,661, filed on Aug.6, 2008, now U.S. Pat. No. 8,491,639, the entire contents of which areherein incorporated by reference in their entirety.

BACKGROUND OF THE INVENTION

The present disclosure relates to spinal fixation systems andparticularly to an anchor device that incorporates multi-axial fixationto the spine.

Several techniques and systems have been developed for correcting andstabilizing injuries to or malformation of the spine. In one type ofsystem, an elongated member such as a bendable rod is disposedlongitudinally along a length of the spine, spanning two or morevertebral levels. In certain applications, the rod is bent to correspondto the normal curvature of the spine in the particular region beinginstrumented, such as the normal kyphotic curvature of the thoracicregion or the lordotic curvature of the lumbar region. In accordancewith such a system, the rod is engaged to various vertebrae along alength of the spinal column by way of a number of anchor devices thatutilize a variety of fixation elements configured to engage specificportions of the vertebra and other bones. For instance, one suchfixation element is a hook that is configured to engage the laminae ofthe vertebra. Another very prevalent fixation element is a screw thatcan be threaded into various parts of the vertebrae or other bones.

Early rod-type spinal fixation systems incorporated anchor devices thatpermitted very limited relative orientations of the rod relative to thefixation element. As these system evolved, various degrees of freedom ofrelative orientation were integrated into the system. For instance, inone system a bone screw may be engaged to the spinal rod at a range ofplanar angles. This so-called variable angle screw allows pivoting ofthe bone screw in a single plane parallel to the plane of the spinalrod. One goal achieved by the variable angle screw is that the surgeoncan apply vertebral fixation elements to the spine in more appropriateanatomic positions.

Another rod-type fixation system utilizes fixation elements having abody that defines a slot within which the spinal rod is received. Theslot includes a threaded bore into which a threaded plug is engaged tosecure the rod within the body of the fixation element. One benefit ofthis type of fixation element is that the fixation element may bepositioned directly beneath the elongated rod, thereby reducing theoverall bulkiness of the implant construct and minimizing trauma to thesurrounding tissue.

On the other hand, these so-called “open back” fixation elements arecapable only of pivoting about the spinal rod to achieve variableangular positions relative to the rod. While this limited range ofrelative angular positioning is acceptable for many spinal pathologies,many other cases require more creative orientation of a bone fastenerrelative to a spinal rod. Certain aspects of this problem are addressedby some prior multi-axial or poly-axial screws that are capable ofvarious three-dimensional orientations with respect to the spinal rod.One type of poly-axial screw design, shown in U.S. Pat. No. 6,537,276 toMetz-Stavenhagen et al., includes a spherical projection on the top ofthe bone screw. An internally threaded receiver member pivotallysupports the bone screw and a spinal rod on top of the sphericalprojection. An inner set screw is tightened into the receiver member topress the spinal rod against the spherical projection to accommodatevarious angular orientations of the bone screw relative to the rod. Asimilar multi-axial screw is disclosed in U.S. Pat. No. 5,466,237 toByrd et al., except an outer nut is provided to secure the rod againstthe head of the bone screw.

In another approach shown in U.S. Pat. No. 4,946,458 to Harms et al., aspherical headed bone screw is supported within separate halves of areceiver member. The bottoms of the halves are held together by aretaining ring. The top of the receiver halves are compressed about thebone screw by nuts threaded onto a threaded spinal rod. One detriment ofthis system is that the spinal rod must be threaded in order to acceptthe compression nuts, which has a tendency to weaken the spinal rod inthe face of severe spinal loads. Harms et al. also describes in U.S.Pat. No. 5,207,678 another multi-axial pedicle screw wherein acompression member is provided between the rod and the head of the screwto exert a force on the screw head to lock the screw against the innerspherical surface of the receiver member.

Yet another approach is illustrated in U.S. Pat. No. 5,797,911 toSherman et al., in which a U-shaped holder is provided that receives abone fastener topped with a crown member. The holder accommodates a rodin a channel above the crown member and a compression member above therod. The compression member presses on the rod and crown member to lockthe fastener against the holder in any of a number of angles in threedimensions with respect to the rod. Another system shown in U.S. Pat.No. 5,733,285 to Errico et al., includes a holder having a tapered andcolleted portion into which a bone fastener head is inserted. A sleeveis provided that translates down around the colleted portion to crushlock the colleted portion around the head of the bone fastener. Thisapparatus is bulky and difficult to manipulate given the externalsliding locking mechanism. It is further dependent on the fit of theexternal sleeve and the relative strength of the collet and its bendingand crushing portions for secure locking of the bone fastener head.

A difficulty that appears to be associated with many of the knownpoly-axial bone screws is that as a result of the poly-axial freedom ofmovement, the U-shaped rod holder tends to ‘flop” relative to the bonefastener. In U.S. Pat. No. 7,087,057, Konieczyinski et al. attempt toaddress this issue by including a snap ring to provide sufficientfriction between the head of the bone fastener and the rod holder so asto hold a relative position therebetween before the holder and fastenerare locked together in use.

There remains a need for a multi-axial or poly-axial fixation system foruse with a spinal fixation system that is simple to construct yet strongenough to withstand harsh spinal loads. There is a further need for afixation system that includes features to temporarily hold the rodholder in position relative to the bone fastener while still allowingmanipulative movement by the surgeon.

SUMMARY OF THE INVENTION

The present disclosure contemplates a spinal fixation system thatincorporates multi-axial fixation characteristics in a low-profile, easyto construct anchor device. The system includes an elongated member,such as a spinal rod, that extends between spinal segments. A series ofanchor devices anchor the rod to the spinal segments, with at least someof the anchor devices providing multi-axial fixation. In one embodiment,the multi-axial anchor device includes a bone engaging fastener that isadapted to engage a portion of the spine. In one specific embodiment,the fastener is a bone screw adapted to be threaded into the pedicle ofa vertebra.

Connection to the spinal rod is provided by way of a yoke that is freeto swivel relative to the fastener. The yoke defines a channel betweenopposing arms of the yoke, with the channel configured to snugly seatthe rod therein. A sleeve is provided that fits about an upper portionof the head of the bone engaging fastener. This upper portion provides aspherical surface to interface with a spherical lower cavity of thesleeve so that the sleeve may adapt a range of spherical angles relativeto the bone engaging fastener as necessary to accommodate the positionof the spinal rod relative thereto.

In a particular configuration, a friction member in the form of a springelement is disposed between the yoke and the outer sleeve disposed overthe head of the fastener. The spring element is configured to releasablyretain the yoke in at least one pre-determined position relative to thefastener. In one specific embodiment, the spring element is in the formof a wave spring that sits within a recess or cavity formed in the outersleeve. The inner diameter of the wave spring engages a lower surface ofthe yoke so that a downward force applied to the yoke produces a forceexerted by the wave spring against the outer sleeve. This force createsa static friction force that resists movement of the yoke relative tothe sleeve, and ultimately relative to the fastener.

Thus, in one feature, the spring element is configured so that slightlytightening the yoke into the ball insert generates a downward force onan apex of the wave spring configuration. The amount of downward forcedictates the amount of force exerted by the spring element against theouter sleeve, which directly correlates to the static friction forcethat resists movement of the yoke. Preferably the static friction forceis sufficiently high to firmly hold the yoke in its position relative tothe fastener, but sufficiently low to allow the surgeon to manuallymanipulate the yoke to a new position as required when building thefixation construct in situ.

One benefit of the device disclosed herein is that it provides for solidanchoring between a spinal rod and a bone engaging fastener at variablespherical angles. A further benefit is that a common clamping element isprovided to clamp the spinal rod and fix the angular position of theanchor device.

Yet another benefit resides in one aspect of the anchor device thatreduces the overall prominence and profile of the components of thedevice. A still further benefit is that the relative angular position ofthe components may be temporarily held during implantation or inanticipation of engagement with a prepared spinal rod. Other benefitscan be discerned from the following written description and accompanyingfigures.

DESCRIPTION OF THE FIGURES

FIG. 1 is a transverse view of a portion of a spine with a fixationsystem utilizing an elongated members engaged between successivevertebrae.

FIG. 2 is a side perspective view of an anchor device according to oneembodiment for use in the fixation system shown in FIG. 1.

FIG. 3 is a top plan view of the anchor device shown in FIG. 2.

FIG. 4 is a side cross-sectional view of the anchor device of FIG. 2.

FIG. 5 is a longitudinal cross-sectional view of the anchor deviceillustrated in FIG. 2 along the longitudinal axis of the elongatedmember.

FIG. 6 is a top plan view of a ball insert element of the anchor deviceshown in FIG. 2.

FIG. 7 is a side elevational view of the ball insert shown in FIG. 6.

FIGS. 8a-8f are side perspective views of a sequence of assembly of thecomponents of the anchor device shown in FIG. 2.

FIG. 9 is a top perspective view of a sleeve component of the anchordevice shown in FIG. 2.

FIG. 10 is a side cross-sectional view of the sleeve shown in FIG. 9.

FIG. 11 is a longitudinal cross-sectional view of a fixture with holdingpins for holding the position of the ball insert relative to the socketduring engagement of the yoke.

FIG. 12 is a longitudinal cross-sectional view of the fixture withholding pins used to crimp or swage the threads of the yoke to fix theyoke to the ball insert.

FIG. 13 is a longitudinal elevational view of a cap with set screw ofthe anchor device of FIG. 2.

FIG. 14 is a top plan view of the cap shown in FIG. 13.

FIG. 15 is a cross-sectional view of the cap of FIG. 14 taken alongviewing line XV-XV.

FIG. 16 is a longitudinal cross-sectional view similar to FIG. 5 showingforces generated to lock the components of the anchor device of FIG. 2.

FIG. 17 is a side elevational view of a fastener inserter tool for usewith one embodiment of the anchor device of the present disclosure.

FIG. 18 is a longitudinal cross-sectional view of the fastener insertertool shown in FIG. 17 engaged to components of the anchor device ofFIG.2.

FIG. 19 is a longitudinal cross-sectional view of the lower end of a rodpersuader tool engaged to a partially assembled anchor device of FIG. 2.

FIG. 20 is an exploded view of an anchor device according to a furtherembodiment incorporating a spring element for temporarily holding theyoke in a position relative to the fastener of the anchor device.

FIGS. 21a, 21b are top and side views of the spring element incorporatedinto the anchor device shown in FIG. 20

FIG. 22 is a cross-sectional view of the assembled anchor device shownin FIG. 20 showing the reaction force generated by the spring elementbetween the yoke and the outer sleeve.

FIG. 23 is a cross-sectional view of the assembled anchor device with analternative reaction force generated by the spring element.

DESCRIPTION OF THE EMBODIMENTS

Reference will now be made to the embodiments illustrated in thedrawings and described in the following written specification. It isunderstood that no limitation to the scope of the invention is therebyintended. It is further understood that the present invention includesany alterations and modifications to the illustrated embodiments andincludes further applications of the principles of the invention aswould normally occur to one skilled in the art to which this inventionpertains.

The present disclosure contemplates a spinal fixation system, such asthe system 10 depicted in FIG. 1. As is known in the art, the fixationsystem 10 spans between successive vertebrae of the spine. An elongatedmember, such as rod 12, extends along the length of the spine andprovides an anchor point for connecting each vertebra to the rod. Therod is typically contoured to approximate the normal curvature of thespine for the particular instrumented spinal segments. Anchor devices 15are provided for connecting the vertebral segments to the rod. Theseanchor devices may include hooks, bolts, screws or other means forengaging a vertebra. For the purposes of the present discussion, theanchor device 15 includes a bone engaging fastener 20 which is a bonescrew, as shown in FIG. 2. The bone screw 20 includes a threaded shank22 configured for threaded engagement within a portion of a vertebra. Ina specific example, the shank is configured for engagement within thepedicle of a vertebra.

The bone engaging fastener or screw 20 further includes a head 24 bywhich the screw, and ultimately the vertebra, is anchored to the spinalrod 12. In accordance with one feature, the head 24 defines a sphericalsocket 26 with a socket opening 28 facing the rod, as shown in FIGS.4-5. The bone screw 20 further defines a central bore 30 intersectingthe socket and extending part way into the threaded shank 22. Atransverse bore 32 extends through the head 24 and across the socket, asbest seen in FIG. 5. The function of the bores 30 and 32 are discussedherein. The head 24 includes a spherical outer surface 34.

It can be appreciated from considering FIGS. 4-5 that the spherical head24 of the bone screw is more than simply hemi-spherical. In other words,the spherical socket 28 subtends a spherical angle of greater than 180°so that socket opening 28 is defined at a chord of the spherical socket.The planar diameter of the opening 28 at the chord is less than theinner diameter of the socket. In a specific embodiment, the sphericalhead subtends a spherical angle of about 240° and the planar chordaldiameter of the socket opening 28 is about 90% the spherical diameter ofthe socket. It can thus be appreciated that a ball element of about thesame spherical diameter disposed within the socket will be retainedwithin the socket, unable to pass through the socket opening. It will beappreciated from the following discussion that a smaller planar chordaldiameter will reduce the range of angulation of the articulatingcomponents of the anchor device.

Of course, a ball element that is too large to pass through the opening28 cannot be readily inserted into the socket 26. The present deviceaddresses this matter by a ball insert element 40, illustrated in detailin FIGS. 6-7. The ball insert 40 defines a central threaded bore 42 thatis provided for connection to a yoke component 50, as described in moredetail herein. The ball insert is generally in the form of a truncatedsphere, whereby the outer surface 44 of the ball insert includes aspherical surface 45 that is sized to closely approximate the sphericalsocket 26, as shown in FIG. 5. Thus, spherical surface 45 defines anouter spherical diameter D₁, that is slightly less than the interiordiameter of the spherical socket 26, but greater than the diameter ofopening 28. As seen more particularly in FIG. 8b , the ball insert 40 isfurther formed to have a cylindrical portion defined by curved surfaces46. The curved surfaces 46 of cylindrical portion define an outerdiameter D₂ about axis A as depicted in FIG. 8b . Axis A in onearrangement is formed to be generally perpendicular to the axis of thecentral threaded bore 42. In accordance with one aspect the maximumdiameter D₂ is slightly less than the planar chordal diameter of socketopening 28 (FIG. 8a ) and defines an insert dimension for placing theball insert 40 into the socket 26 as will be defined. While curvedsurfaces 46 are preferably formed to define a cylindrical insertdimension D₂, it should be appreciated that other configurations may beconsidered, such as one or more flattened outer surfaces, provided thata maximum insert dimension such as diameter D₂ is formed less than themaximum dimension of the socket opening 28.

The benefit of this configuration for the ball insert 40 can be readilyappreciated upon consideration of the sequence in FIGS. 8a-8c depictinginsertion of the ball insert 40 into the socket 26 of the bone screw 20.As shown in FIG. 8b , the ball insert 40 is rotated at least 90° so thatthe insert dimension D₂ with curved surfaces 46 is aligned to passthrough planar chordal opening 28 and into the socket 26. The insertdimension D₂ is oriented so that axis A of ball insert 40 is essentiallyaligned along the axis of the bone screw. The depth of the socket 26 issufficient to fully receive the rotated ball insert 40 so that thespherical surface 45 exposed in the view of FIG. 8b is within thesocket. Then, in the final step shown in FIG. 8c , the ball insert 40 isfurther rotated at least 90° so that the threaded bore 42 faces upwardthrough the socket opening 28. In this position, the spherical surface45 of the ball insert is juxtaposed with the interior of the sphericalsocket 26, as shown in FIG. 5, and the ball insert 40 is captivelyretained in the socket 26 for swivel movement therewithin.

The ball insert 40 is further provided along axis A as seen in FIG. 8awith a transverse bore 48 that may be aligned with the transverse bore32 in the spherical head 24 of the bone screw, as shown in FIG. 5 andFIG. 8a . As can be seen from the figures, the ball insert is truncatedat the top and bottom of the insert. However, the ball insert in thisarrangement is not symmetric—i.e., more of the top of the spherical ballis truncated than the bottom of the ball. Further, as a result of theformation of the curved cylindrical surfaces 46, the lower truncatedsurface has indentations 49 as illustrated in FIG. 7. When the ball 40is rotated as depicted in FIG. 8b , the indentations 49 may be directedtoward the bottom of socket 26 and are not visible through the socketopening.

Returning to FIGS. 4-5, the anchor device 15 further includes a yoke 50having a threaded stem 52 configured to engage the threaded bore 42 inthe ball insert 40. The stem is provided with a shoulder 53 thatpreferably abuts the ball insert 40 when the stem 52 is fully threadedinto the bore 42 of the insert. The yoke 50 includes yoke arms 54 a, 54b that define a yoke channel 55 therebetween. The gap between the arms54 a, 54 b, and consequently the width of the channel, is sized toclosely fit the spinal rod 12, as best seen in FIG. 5. The arms 54 a, 54b define internal threads 56 at the upper open end of the yoke 50 forengaging a set screw 80, as described below. A bore 57 passes throughthe threaded stem 52 that is aligned with the bore 30 in the bone screwwhen the yoke is mounted on the ball insert.

As shown in FIGS. 8d -8 e, a sleeve 60 is interposed between the yoke 50and the head 24 of the bone screw 20. As further shown in FIGS. 9 and10, the sleeve 60 defines a lower cavity 62 that has a sphericalconfiguration to substantially match the spherical outer surface 34 ofthe screw head 24. Sleeve 60 sits on the outer surface 34 for slidingmovement thereon, and serves as a clamping element for the rod 12relative to the yoke as will be described. The sleeve further defines anupper cavity 64 that generally parallels the outer surface of the yokearms 54 a, 54 b, as seen in FIG. 5. The upper face of the sleeve 60defines opposite rod grooves 66 sized to receive the spinal rod 12therein. The lower face of the sleeve defines opposite notches 68 thatare oriented 90° from the rod grooves 66. The notches 68 are arranged toalign with the transverse bores 32 and 48 when the anchor device isassembled. The notches and bores are sized to receive retaining pins 155(FIG. 11) as described in more detail herein. In a preferredarrangement, sleeve 60, is provided with opposing recessed surfaces 63that engage the arms 54 a, 54 b of the yoke 50 to key the sleeve 60 toyoke 50 in a manner that allows common swivel movement of the yoke 50and sleeve 60 relative to the screw head 24.

As depicted in FIGS. 8d -8 e, after the ball insert 40 is properlyaligned and captively retained as shown in FIG. 8c , the yoke 50 mayengage the insert 40 to form an assembly therewith. In accordance withthe preferred manner of assembly of the anchor device 15, the threadedstem 52 of the yoke is extended through the sleeve 60 with the sleevekeying surfaces 63 aligned with the yoke arms 54 a, 54 b. The threadedstem 52 is then threaded into engagement with the threaded bore 42 ofthe ball insert. In order to achieve this threaded engagement it isnecessary to hold the ball insert 40 as the stem 52 of the yoke isthreaded into the bore 42. Thus, in one aspect the ball insert 40 isoriented within the spherical socket 26 so that the transverse bores 48in the insert are aligned with the transverse bores 32 in the screwhead. When the bores are aligned, pins 155 may be pushed therethrough,taking care that the pins do not extend into the threaded bore 42, asillustrated in FIG. 11. Arms 157 of a forceps-like tool may be used tointroduce the pins into the bores.

With the pins 155 in position, the sleeve 60 may be placed over the headof the bone screw with the notches 68 aligned with the pins 155. Theyoke is then extended through the sleeve with the stem engaging thethreaded bore 42 of the ball insert. The pins 155 resist rotation of theball insert 40 as the stem is threaded into the bore. The yoke 50 isthreaded into the ball insert until the shoulder 53 contacts the upperface of the ball insert 40 as shown in FIGS. 4-5.

In an additional feature, the pins 155 may be used to crimp, swage ordeform the threads of the stem 52 of the yoke 50. Thus, the tool arms157 may be pressed toward each other so that the pins 155 contact thethreaded stem 52, as shown in FIG. 12. When the threads are distortedthe stem 52 of the yoke cannot back out or unthread from the ball insert40. Once the yoke and ball insert have been locked together, the pins155 can be removed. It is understood that this initial assembly of theanchor device, namely the steps shown in FIGS. 8a -8 e, occur prior tointroduction of the anchor device 15 into the spine, preferably by thesupplier. It can also be appreciated that once the yoke 50 is lockedwith ball insert 40, the ball insert 40 is free to swivel within thefastener socket 26 allowing the yoke attached thereto to freely angulatein multiple directions. Since sleeve 60 is keyed to yoke 50 it likewisefreely slides on outer surface 34 of fastener head 24 as the yoke 50moves, until the anchor device components are locked in use.Furthermore, even though the ball insert 40 is free to swivel withinsocket 26, once the yoke 50 is attached the insert 40 remains captivelyretained since the insert 40 will not be able to move to a positionwhere its insert dimension L₁ is aligned with the socket opening 28.

Returning again to FIGS. 4-5, the assembly of the rod 12 to the fastener20 is shown. The rod 12 is initially placed between the arms of the yoke50 to rest on the rod grooves 66 of the sleeve 60. The yoke channel 55may then be closed, securing the rod within. In accordance with afurther feature a cap 70 is fitted over the top of the yoke arms 54 a,54 b. The cap 70 as further detailed in FIGS. 13-15, includes agenerally cylindrical skirt 74 that fits snugly around the arms 54 a, 54b to prevent the arms from splaying outward as set screw 80 is threadedinto the arms. The skirt 74 is preferably provided with diametricallyopposed flats 75 that correspond to the transverse opening of the yokechannel 55, as best seen in FIG. 8f . The flats 75 define rod grooves 72that align with, but do not contact, the rod 12 when it is situatedwithin the yoke channel 55.

The cap 70 includes an upper boss 76 that defines an enlargedcircumferential interior groove 78. This groove is sized to receive aretaining ring or snap ring 90 therein, as seen in FIG. 5 and FIG. 15.The groove is axially enlarged or lengthened so that the snap ring 90may translate up and down within the boss 76 for reasons explainedbelow.

The set screw 80 is provided with a threaded stem 82 that is configuredto engage the internal threads 56 of the yoke arms 54 a, 54 b.Preferably the threaded engagement between set screw and yoke are in theform of buttress threads, as depicted in FIGS. 4-5. The buttress threadsminimize the outward force produced as the set screw is threaded intothe yoke. Thus, the use of buttress threads help minimize any splayingof the yoke arms that might otherwise occur when the set screw 80 isthreaded tightly into the yoke 50. In addition as shown in FIG. 15, thebottom of the set screw is recessed upwardly of the bottom of the skirt74 of cap 70. Thus, when cap 70 is placed over the arms 54 a, 54 b ofyoke 50, not only does the close fit of the skirt 74 relative theretoprevent splaying as noted, but skirt 74 also serves as a guide to alignthe threads 82 of set screw 80 into the threads 56 of the yoke 50,thereby also reducing the risk of disadvantageous cross-threading.

The set screw 80 includes a pressure face 83 that contacts and exerts asecuring force against the spinal rod 12. The pressure face 83 as wellas the rod surface may exhibit surface features intended to enhance thefixation between set screw and rod, as is known in the art. Inparticular, a surface roughness may be provided that becomes deformed orcold formed when the set screw is tightened onto the rod. This featurehelps prevent the rod from slipping axially (along its length) withinthe anchor device 15.

The set screw 80 defines a bore 84 therethrough. The upper portion 86 ofthe bore may be configured to receive a driving tool, such as with hexor TORX surfaces.

Like the cap 70, the set screw 80 defines a circumferential groove 88(FIG. 4) configured to receive the retaining ring 90 therein. However,unlike the cap groove 78, the groove 88 in the set screw is preferablysized to closely fit the snap ring. Thus, while the snap ring 90 is heldby the set screw, the snap ring is free to translate within theelongated cap groove 78. The elongated groove 78 is thus intended toallow the set screw 80 to fully engage the rod 12 while the cap 70essentially floats by virtue of the snap ring 90 translating withingroove 78. Thus, the cap 70 effectively exerts no force on the rod 12 oron the top surface of the yoke 50, even if some contact is made.

The set screw 80 generates the force that locks the ball insert 40within the spherical socket 26 at the desired angular orientation, andthat further locks the spinal rod 12 within the anchor device 15. Inparticular, once the anchor device 15 has been fully assembled about therod 12, as best seen in FIG. 16, the set screw 80 is tightened withinthe yoke 50. As the screw is tightened, it presses against the rod 12,clamping it between the pressure face 83 of the set screw and the rodgrooves 66 in the sleeve 60. As the set screw is driven further into theinternal threads 56 of the yoke 50, the set screw pushes the rod 12downwardly until the lower cavity 62 of the sleeve 60 is firmly engagedto the outer surface 34 of the head 24 of the bone screw generatinglocking force, F1.

At this point the sleeve 60 and rod 12 can move no further toward thebone screw 20. Therefore, any further tightening of the set screw isreacted by the yoke itself. As the set screw is driven further into theyoke internal threads (i.e., advancing toward the head of the bonescrew) this reaction force pulls the yoke upward. While the yoke ispulled upward with continued rotation of the set screw, the stem 52 ofthe yoke pulls the ball insert 40 upward, owing to the fixed engagementbetween the yoke stem and the ball insert. As the ball insert is pulledupward, it bears forcefully against the upper face of the sphericalsocket 26, with a force F2 clamping the socket wall between the sleeve60 and the ball insert 40 and thereby locking the ball insert 40 andyoke 50 relative to fastener 20. Any tendency of the socket 26 toattempt to gap at the socket opening 28 is resisted by the sleeve 60that is already in firm engagement about the outer surface 34 of thescrew head.

It can thus be appreciated that the entire anchor device can beadjustably secured in a fixed relationship simply by rotation of the setscrew 80. As the set screw is threaded into the yoke threads it ensuressolid clamping of the bone screw head 24 between the lower cavity 62 ofthe sleeve 60 and the spherical surface 45 of the ball insert 40,regardless of the angular orientation of the yoke and rod relative tothe screw. The rod itself is firmly clamped between the set screw andthe lower sleeve. It can further be appreciated that the entire anchordevice may be tightened by simply tightening the set screw.

In use, the bone screw and sleeve assembly of FIG. 8e is providedtogether with one or more suitably sized rods 12 and a cap 70 so that aspinal fixation system 10 may be implanted into a patient. The surgeonmay insert the bone screw assembly with a suitable screw inserter 140 asshown, for example, in FIGS. 17-18. The screw inserter 140 includes anouter sleeve 142 and an inner shaft 144 rotatably disposed within thesleeve. As shown in the view of FIG. 18, the end 146 of the outer sleeve142 is configured to contact the proximal upper surface of the sleeve60. The outer sleeve 142 is fixed to a handle 150, while the inner shaftis fastened to a tightening knob 152 that is rotatably supported on thehandle. The inner shaft 144 includes a pin end 148 that is sized toextend through the bore 57 in the yoke 50 and into the bore 30 at thebase of the spherical socket 26. The pin end 148 ensures co-axialalignment of the driving tool 140 and the bone screw threaded shank 22.The inner shaft further includes intermediate threads 149 axially offsetfrom the pin end 148. These threads 149 are arranged to engage theinternal threads 56 of the yoke arms 54 a, 54 b.

The threads 149 on the inner shaft 144 of the tool 140 operate similarto the set screw 80. Specifically, as the threads are driven into theinternal threads 56 of the yoke 50, the pin end 148 reacts against thebottom of the bore 30 in the bone screw to generate an upward force onthe yoke 50. As the yoke is pushed upward, it pulls the ball insert 40with it, thereby driving the insert into the spherical socket. When theinner shaft 144 has been fully tightened, the screw inserter tool 140,yoke 50, ball insert 40 and bone screw 20 form a rigid connection. Thehandle 150 of the outer sleeve 142 may then be used to drive the bonescrew into the vertebral bone, either manually or with the assistance ofan additional driving tool after a suitable hole has been drilled in thepedicle of a vertebra.

Once the bone screw 20 is threaded in position into the spine, the nextstep to completing the fixation system, such as system 10 shown in FIG.1, is to introduce the rod 12 into the yoke 50 of the anchor device 15.The rod may be contoured to match the normal curvature of the spine,either in lordosis or kyphosis depending upon the instrumented vertebrallevel. In some cases, the spine exhibits a lateral curvature, such asscoliosis, that is preferably corrected, at least partially, by thefixation system 10. Thus, in certain cases, the rod 12 itself may belaterally offset from the position of the bone screw engaged within theunderlying vertebra. In these cases, the variable angle capabilities ofthe anchor device of the present disclosed embodiment come into play.

To accomplish the introduction of the rod 12 into the yoke channel 55 ofthe yoke 50, a rod persuader tool 185 is provided, as shown in FIG. 19.The rod persuader tool 185 includes an outer tube 186 and an inner tube192 concentrically disposed within the outer tube for relative axialmovement. The outer tube 186 defines a rod notch 189 at its bottom end187. The inner tube 192 defines a slot 193 that forms legs 194 at thedistal end. The legs define an inner shoulder 195 that is configured tosuitably engage the partially assembled anchor device. The innershoulders 195 may engage a groove (not shown) in the outer surface 34 offastener socket 26. In another embodiment, the yoke 50 may be modifiedto have a groove (not shown) that may be engaged by the inner shoulders195. In either embodiment, the legs 194 are configured to partiallyencircle and firmly grasp the partially assembled anchor device, whilethe slot 193 accommodates the initial presence of the rod 12 within theyoke channel 55. A guide pin 190 spans the diameter of the outer tube186 and fits within the slot 193 to control the relative axial movementbetween the outer tube 186 and the inner tube 192. A suitable mechanismis provided to move the outer tube 186 downward axially relative toinner tube 192. As the outer tube 186 moves downward, it forces the rod12 into the yoke channel 55 by lower notch 189 and into the rod groove66 of the sleeve 60.

With the rod 12 suitably placed into the yoke 50, the spinal fixationdevice 10 may then be completed. Cap 70 as shown in FIG. 8f is thenassembled to the yoke 50, as described above with reference to FIGS.4-5, to lock the rod 12 relative to the yoke 50 and the yoke 50 relativeto the bone fastener 20. It should be appreciated that the spinalfixation device 10 as particularly described herein has the advantage ofestablishing a low profile, since the outer surface of the screw head 24may be driven down relatively deeply into the pedicle of the vertebra,while still maintaining swivel movement of the yoke 50 until the setscrew 80 is tightened. Furthermore, the relatively large surface area ofspherical surface 45 of the ball insert 40 tightly pressed against theinterior surface of the screw socket 26 provides for a very rigidconstruct for locking the polyaxial motion of the yoke 50 relative tothe screw 20.

In another embodiment, an anchor device 300, shown in FIGS. 20-23,incorporates a friction member in the form of a spring element 340disposed between the yoke 330 and the outer sleeve 320. The device 300is configured similar to the anchor devices described above, including abone screw 305 in which the head 307 forms a spherical socket to receivea ball insert 310. The yoke 330 includes a threaded stem 332 to engagethe ball insert within the head of the bone screw, in the mannerpreviously described. As explained above with respect to the embodimentof FIG. 20, it is desirable to provisionally maintain the yoke in apredetermined orientation with respect to the bone screw. The frictionmember of this embodiment provides a static friction force that is afunction of the threaded engagement between the yoke and the ballinsert. In other words, as the yoke stem is tightened into the ballinsert, the static friction force generated by the spring element 340increases, thereby increasing the force temporarily holding the yoke inposition relative to the fastener.

In the embodiment shown in FIG. 20, the spring element 340 is in theform of a wave washer or wave spring disposed between the lower surface334 of the yoke and an opposing surface of the outer sleeve 320. Asshown in detail in FIGS. 21a -21 b, the spring element 340 includes aring-shaped body 341 having an outer edge 342 and an inner edge 344. Thespring element is bent along one axis to form an apex 346 that is offsetor in a different plane than opposite portions 348. The spring elementthus operates as a wave spring in that a force F applied at the apex 346produces reaction forces R at the opposite portions 348, as depicted inFIG. 21 b.

The function of this reaction force R is illustrated in FIG. 22. Thestem 332 of the yoke 330 extends through the center opening 345 of thespring element 340 to threadedly engage the ball insert 310 in themanner described above. The outer sleeve 320 is captured between theyoke and the head 307 of the bone screw 305, also as described above. Asthe yoke stem is threaded into the ball insert, the lower surface 334 ofthe yoke bears against the inner edge 344 of the spring element. Thus,the downward force F′ exerted by the yoke as it is threaded into theball insert produces the force F on the apex 346 of the spring element.The resulting reaction force R is exerted by the opposite portions 348of the spring element against an inner surface 327 of a cylindricalcavity 326 formed in the outer sleeve 320. This reaction force Rincreases the static friction force between the ring body 341 and theouter sleeve 320, as well as between the ring body and the yoke 330. Itcan also be appreciated that a commensurate static friction force isproduced at the interface between the yoke lower surface 334 and theinner edge 344 of the spring washer. Thus, the presence of the wavespring 340 provides an adjustable friction force between the yoke andthe outer sleeve to temporarily fix the relative orientation between thetwo components.

In addition, the downward force F bears down on the outer sleeve 320 andmore particularly on the lower surface 322 of the inner sleeve to pressagainst the outer surface 308 of the head 307 of the bone screw. Thispressure helps hold the position of the outer sleeve relative to thebone screw. Thus, the sum of the forces generated by the spring element340 provisionally holds the yoke and outer sleeve in a predeterminedposition by loosely tightening the yoke stem into the ball insert. Theamount of reaction force R exerted by the spring element, and thereforethe amount of static friction force produced by the element, is afunction of how far the yoke stem is threaded into the ball insert.

The static friction force produced by the spring element 340 can bemanually overcome by pressure against the yoke 330, such as by pushingthe top of the yoke laterally to adjust its angular orientation relativeto the bone screw. When the lateral pressure is removed, the staticfriction will hold the yoke in its new position. Thus, the springelement 340 allows the surgeon to provisionally position the yoke as thefixation construct is assembled in situ. Once the yoke has been properlypositioned to receive a spinal rod, for instance, the yoke can be fullytightened into the ball insert to clamp the components of the entireanchor device 300 together.

In order to accommodate the spring element 340 the outer sleeve 320 maybe modified from the configuration of the prior disclosed embodiments.The lower surface 322 may have the same configuration for engaging theouter surface 308 of the bone screw head 307. The upper surface 324 isabbreviated by the addition of the cylindrical cavity 326 that is sizedto receive the ring body 341 of the spring element. However, the uppersurface 324 serves the same function as in the previous embodiments.Specifically, the lower surface 334 of the yoke bears against the uppersurface 324 of the sleeve as the yoke stem is fully tightened into theball insert 310. When the yoke stem is fully tightened, the springelement 340 becomes essentially superfluous. The final clamping of thecomponents of the anchor device 330 is thus accomplished by theinteraction of the ball insert, the inner and outer surfaces of the bonescrew head, the upper and lower surfaces of the outer sleeve and thelower surface of the yoke, all as described above.

It can be appreciated that the spring element permits adjustment of thestatic friction force operable to hold the yoke in position relative tothe fastener. Tightening the yoke into the ball insert increases thestatic friction force, while loosening the yoke decreases the force. Thefriction force can be adjusted as necessary by the surgeon.

In the embodiment illustrated in FIG. 22, the reaction force R isexerted essentially parallel to the longitudinal axis of the constructagainst the surface 327 of the cylindrical cavity 326. In an alternativeembodiment, the outer sleeve 320 can be modified to remove the upperportion 320′ of the sleeve, with the surface 327 essentially forming thetop of the sleeve. In this alternative embodiment, the cavity 326 isessentially eliminated. The spring element will nonetheless be readilyretained when the components are initially assembled, since thewasher-like configuration of the element 340 allows the yoke stem 322 tobe threaded through the center opening 345 in the element.

In another embodiment, the cavity 326 is sized so that the reactionforce R is a generally radial force, as shown in FIG. 23. In thisversion, the opposite portions 348 of the spring element bear againstthe cylindrical wall 328 of the cavity. Although the reaction force isradial, rather than axial as shown in FIG. 22, a static friction forcestill arises between the washer and the sleeve that provides the sametemporary holding force.

In a specific embodiment, the ring body 341 of the spring element can beformed of a medical grade titanium alloy, such as Ti-6Al-4V. The ringmay be 0.020 in. thick with an outer diameter of 0.533 in. and an innerdiameter of 0.493 in. The ring body may be bent so that the apex 346 isoffset from the outer portions 348 by about 0.080 in.

In the illustrated embodiment, the wave spring configuration of thespring element 340 contemplates one bend at the apex 346 with twoopposite portions 348. With this embodiment, the reaction force R isexerted at only two diametrically opposite locations within the cavity348 of the outer sleeve 340. In alternative embodiments, multiple bendsare contemplated to produce multiple undulations around the perimeter ofthe ring body 341. These multiple undulations result in multiple contactpoints between the spring element and the cavity 348 of the outersleeve, and therefore multiple locations at which the reaction force Ris applied.

In addition, the anchor device 300 may also be formed to provide forinsertion into or removal from a bone. A central bore 352 may be formedthrough yoke 330, the bore 352 opening at the U-shaped channel at itsupper end and opening at the bottom of threaded portion 332 at its lowerend. Formed into the lower spherical surface of the head 307 of bonescrew 305 is a recess 354, configured preferably to have a Torx shape,although other suitable configurations may be also be used. Recess 354aligns with bore 352 when the yoke 330 is oriented generally verticallyalong the axis of bone screw 305 so that a suitable tool, such as a Torxwrench, may be introduced through bore 352 and engage recess 354 toenable implantation of the bone screw 305 into or removal from a bone.

While the invention has been illustrated and described in detail in thedrawings and foregoing description, the same should be considered asillustrative and not restrictive in character. It is understood thatonly the preferred embodiments have been presented and that all changes,modifications and further applications that come within the spirit ofthe invention are desired to be protected.

What is claimed is:
 1. An anchor device for anchoring an elongated rodto the spine, comprising: a fastener having a bone engaging portion anda head, said head defining a socket and having a curved outer surface;an insert captively retained in said socket and configured for swivelingtherein; a yoke having a top surface and a rod receiving channel thereinand coupled to said insert for articulating movement relative to saidfastener, said yoke including a lower surface facing said outer surfaceof said head of said fastener; a sleeve coupled to and extending atleast partially around said yoke and having an upper surface and acurved inner lower surface configured to be supported by said curvedouter surface of said head for common swivel movement of said sleeve andsaid yoke relative to said fastener head, said upper surface of saidsleeve being disposed between the top surface of said yoke and thecurved outer surface of said fastener; a friction member disposedbetween said yoke and said sleeve and supported by said sleeve forapplying a static friction force between said sleeve and said fastenerto frictionally maintain said yoke in a movable position relative tosaid fastener; and a tightening element for securing said elongate rodwithin said yoke while overcoming said static force and locking saidyoke relative to said fastener.
 2. The anchor device of claim 1, whereinsaid friction member includes a spring element.
 3. The anchor device ofclaim 2, wherein said spring element is a wave spring.
 4. The anchordevice of claim 1, wherein said tightening element is a fastenercooperating with said yoke to contact and exert a securing force againstsaid elongate rod.